Executive Summary of EIA & EMP Report - KSPCBkspcb.kar.nic.in/PH/EXE-SUM-ENG_MCFL_30112017.pdfPoly Carboxyl Ether project at Mangalore, Karnataka By Panambur ... Ammonium Bi-Carbonate

1. Energy improvement project of Ammonia and Urea plant,

2. 1 million t/y DAP/NPK project

3. Poly Carboxyl Ether project at Mangalore, Karnataka

By

Panambur, Mangalore - 575010 Submitted by:

EIA Consultant:

EQMS INDIA PVT. LTD. INDIA

304-305, 3rd Floor, Plot No. 16, Rishabh Corporate Tower, Community Centre, Karkardooma, Delhi – 110092

Phone: 011-30003200, 30003219; Fax: 011-22374775 Website: www.eqmsindia.com ; E-mail – [email protected]

Executive Summary

of

EIA & EMP Report

August-2017

http://www.eqmsindia.com/

mailto:[email protected]

Energy improvement project of Ammonia and Urea plant, Brown field DAP/NPK project, Poly Carboxyl Ether project at Mangalore, Karnataka

Doc No.: Exe Summary

Rev No. 0

Issue Date: 20.08.2017

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EQMS INDIA PVT LTD

Executive Summary

Introduction

Mangalore Chemicals & Fertilizers Ltd (MCF) is an 'Adventz' Group Company, a large

and diversified business house. The main products of MCF are Urea, Di-Ammonium

Phosphate (DAP), NP 20:20:00:13, Ammonium Bi-Carbonate (ABC) - Food grade,

Sulphuric Acid, Specialty Mixtures of Plant Nutrients consisting of Water Soluble

Fertilizers, Micronutrients & Soil Conditioners and an Industrial Product called

Sulphonated Naphthalene Formaldehyde (SNF) used in construction industry. MCF is an

ISO 14001, OHSAS 18001 and ISO 22000 certified Company.

Project Location

MCF is the only manufacturer of chemical fertilizers in the state of Karnataka. The factory

is strategically located at Panambur, 9 km north of Mangalore City, along the National

Highway 66, opposite to the New Mangalore Port Trust. Proposed project will be

implemented inside the premises of Mangalore Chemicals and Fertilizers.

Terms of Reference Issued by MoEF- EAC

As per the Environmental Impact Assessment Notification, S.O. 1533, 14th September

2006, Schedule – I, the fertilizer industry falls under the Category 5 (A).

Based on the application submitted to MoEF and presentation made in 11th EAC held on

20th and 21st July 2016, MoEF has issued TOR on 23rd September 2016 vide its letter no

J-1011/159/2016-IA II (I). The EIA study has been conducted in-line with the approved

ToR by EAC (MoEF) and taking into consideration the structure of the report given in the

EIA Notification 2006.

Project Description

Energy improvement Project of Ammonia & Urea plants by modernization and capacity

enhancement of Ammonia from 2,47,500 t/y to 3,28,500 t/y and Urea from 4,29,000 t/y

to 5,69,400 t/y. :

Government of India announced new Urea policy No. 12012/1/2015-FPP dated 25-05-

2015 which mandated all Ammonia, Urea manufacturer to improve the energy norms to

particular levels by 2018-19. The norm prescribed for MCF vintage is 6.5 Gcal/t of urea

from present 6.9015 Gcal/t. As the operation profitability depends only on actual energy

consumption and payment of all subsidies are energy dependent, it becomes necessary

for manufacturers like MCF to bring down energy norm to best achievable industry levels

to continue profitable operation. Current energy consumption for Urea production at

MCF is 6.5 Gcal/t and MCF intends to do energy improvement revamp of existing

Ammonia / Urea plants to reduce its energy consumption from present levels.

Also, Urea is an important fertilizer segment. The supply/demand gap is huge and more

than 8 million tons of urea imports are done as of now. The estimated total demand



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EQMS INDIA PVT LTD

supply gap in 2015- 2016 was 8.2 Million MT of urea alone. Government of India is

bound to support this industry through conducive policies/subsidies. All southern states

of India namely Karnataka, Tamilnadu, Kerala and Andhra Pradesh have enough

demand for Urea. In view of this, MCF proposes capacity enhancement of Ammonia

from 2,47,500 t/y to 3,28,500 t/y and Urea from 4,29,000 t/y to 5,69,400 t/y. The capacity

enhancement proposed by MCF will help towards filling the supply/demand gap.

Additional CO2 required for proposed capacity of 5,69,400 t/y of Urea will be recovered

from reformer flue gas by Carbon dioxide Recovery (CDR) unit of 250 MTPD.

New DAP/ NPK plant

There is increasing demand of DAP/NPK fertilizers in the country. The estimated total

demand supply gap of DAP/NPK would be 11 Million MT by 2017-2018. The proposed

expansion project of DAP/NPK would contribute in reducing the dependence on import

of DAP/NPK fertilizers.

New PCE Plant

Higher grade (> M45 Grade) concrete requires different type of admixtures known as

super plasticizers. Poly Carboxyl Ether (PCE) acts as Super plasticizers and is currently

being imported in the country. The proposed new facility within MCF complex would be

contributing in our country’s “Make in India” Program.

S. No. Plant Capacity(TPA) Methodology

Existing Additional Total

1. Ammonia 2,47,500 81,000 3,28,500 Revamp

2. Urea 4,29,000 1,40,400 5,69,400 Revamp

3. DAP/NPK (Multi grade) (16:20 & 20:20)

4,01,500 10,00,000 14,01,500 Additional Production stream

4. Poly Carboxyl Ether (PCE)

---- 18,000 18,000 New plant

5 Sulphuric Acid 1,46,000 --------------- 1,46,000 Existing Plant

6 Ammonium Bicarbonate (ABC)

24,750 ------------- 24,750 Existing Plant

7 Sulphonated Naphthalene Formaldehyde

85,000 ------------- 85,000 Existing Plant

8 Specialty mixtures of plant nutrients

2,21,000 ------------- 2,21,000 Existing Plant



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EQMS INDIA PVT LTD

Land: The proposed project site is located within the premises of Mangalore Chemicals

and Fertilizers Ltd. No additional land will be required for this project. MCF is located in

the Karnataka Industrial Area Development Board notified Baikampady/ Panambur

industrial area, Mangalore, Dakshina Kannada (Mangalore Industrial Cluster).

Power: The present power requirement is 36MW. After implementation of proposed

projects, power requirement for Ammonia and Urea plants will reduce by about 6 MW.

This will cater to the requirement of the new DAP/NPK and PCE plants.

So no additional power will be required for this project.

Water: Presently, water is supplied by Mangalore City Corporation. No additional water

drawl due to the proposed plants. The marginal increase in the water requirement after

the commissioning of the plants will be met by existing wastewater recovery unit.

Manpower: The unit proposes to provide employment to various skilled and unskilled

people. The existing employment at the site is 680 no of people and proposed

employment generation from the project is estimated to be 200 no of people including

contract labor during operation phase.

ETP Plant: In Mangalore Chemicals & Fertilizers Ltd., (MCF), the Liquid Effluent

streams generated is only from Ammonia, Urea and Water Treatment Plants. The

Ammonium Bi-carbonate and Di-Ammonium Phosphate Plants are designed to have

zero effluent discharge. In Di-Ammonium Phosphate (DAP) Plant a part of ammonia and

urea bearing effluent from Urea/Ammonia plant is used as process condensate. MCF

already installed the ETP in existing plant and the same will be used for the proposed

projects also. The treated effluent will be reused as cooling water makeup.

Sewage Treatment Plant: MCF has put up a centralized sewage treatment unit with the

capacity of 300KLD. The combined sewage from the factory is collected in the sump

tanks and pumped to the bar screen chamber and oil trap to remove floating solids and

oil traces respectively. After this preliminary treatment the effluent is fed to equalization

tank. Effluent from the equalization tank is fed to the Membrane Bio-reactor (MBR) tank.

The treated water is reused in cooling tower as makeup. The additional sewage

generated (about 5 m3/d) after the implementation of the proposed projects will be

treated in the existing STP.

Description of Environment

Baseline data was generated during the period Dec 2016 to Feb 2017. Area covering 10

km radius around the Unit was considered for EIA study. Data was generated by

following the standard procedures of the Ministry of Environment & Forests and the

Central Pollution Control Board.

The altitude of study area varies from 0 to 121 m above mean sea level. The altitude of

project site is 19 to 27 m above MSL. Physio graphically, the study area is characterized

by plain and flat to undulated. The drainage of the study area (10 km radius) is mainly



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controlled by the river i.e. Gurupura River, which are flowing in South-East direction. Sea

coast is 2 km away from the site in west direction. As per the Hazard Risk & Vulnerability

Assessment Atlas, the project site and the surrounding 10 km radius study area lies in

zone-III (Moderate risk Zone).

Meteorology: The predominant wind direction at Mangalore is from E, SE during

morning time in all the months. The second most predominant wind direction is from W,

NW during evening time. The mean wind speed ranges from 8.4 to 9.2 kmph during

winter season, 8.3 to 8.6 kmph during monsoon and 8.9 to 9.8 kmph in pre-monsoon

season.

Air Environment: The PM10 level in all the monitoring location of the study area recorded

are within the NAAQS level (100µg/m³). The PM2.5 level in all the monitoring location of

the study area recorded are within the NAAQS level (60µg/m³). SO2 and NOx levels in all

monitoring locations were found within the NAAQS (80 µg/m³). The minimum, maximum,

average and 98 percentiles of the PM10, PM2.5, SO2 and NOx recorded in study area are

tabulated below:

Location

Code Location

PM2.5 (g/m3) PM10 (g/m3)

Min Max Mean 98%tile Min Max Mean 98%tile

AAQ-1 Project Site 24 41 32 40 56 85 74 85

AAQ-2 Lalbagh 20 34 27 34 48 69 58 68

AAQ-3 Kulur 22 39 30 37 53 82 64 78

AAQ-4 Marakada 18 36 25 34 44 73 57 72

AAQ-5 Kodikal 18 28 23 27 40 69 54 67

AAQ-6 Kulai 21 37 28 35 46 76 59 74

AAQ-7 Purkodi 20 34 26 33 41 72 56 70

AAQ-8 Baikampady 23 46 36 45 58 92 78 91

Location

Code Location

SO2 (g/m3) NOx (g/m3)

Min Max Mean 98%tile Min Max Mean 98%tile

AAQ-1 Project Site 6.7 10.2 8.6 10.2 13.8 17.7 16.0 17.5

AAQ-2 Lalbagh 5.0 9.4 7.2 9.3 8.5 14.3 12.5 14.3

AAQ-3 Kulur 4.1 7.4 6.1 7.3 11.5 15.2 13.0 14.9

AAQ-4 Marakada 5.0 8.6 6.9 8.6 8.7 14.5 12.3 14.4

AAQ-5 Kodikal 4.0 6.8 5.3 6.8 10.1 14.8 12.1 14.8

AAQ-6 Kulai 4.3 8.2 6.4 8.1 10.2 16.5 13.0 16.4

AAQ-7 Purkodi 4.3 7.7 6.0 7.6 8.3 13.4 11.0 13.2

AAQ-8 Baikampady 5.5 9.8 7.8 9.7 11.4 18.6 15.7 18.4



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Location

Code

Location

Name

NH3 (µg/m³)

CO,

mg/m3

(1hrs

Conc.)

HC (µg/m³) HF

(µg/m³) Methane Non-

methane

Min Max Mean 98

%tile

Mean

Value

Mean

Value Mean Value

Mean

Value

AAQ-1 Project Site 14.2 29.7 22.1 29.0 <0.1 <0.1 <0.1 <0.1

AAQ-2 Lalbagh 10.0 19.2 13.4 18.8 <0.1 <0.1 <0.1 <0.1

AAQ-3 Kulur 10.8 21.6 15.6 20.9 <0.1 <0.1 <0.1 <0.1

AAQ-4 Marakada 10.4 23.0 14.0 21.9 <0.1 <0.1 <0.1 <0.1

AAQ-5 Kodikal 9.2 21.2 13.6 20.8 <0.1 <0.1 <0.1 <0.1

AAQ-6 Kulai 10.0 24.4 17.5 23.7 <0.1 <0.1 <0.1 <0.1

AAQ-7 Purkodi 9.1 18.6 12.2 18.3 <0.1 <0.1 <0.1 <0.1

AAQ-8 Baikampady 11.5 27.4 19.2 26.8 <0.1 <0.1 <0.1 <0.1

NAAQ Standard: PM10 (100 µg/m3), PM2.5 (60 µg/m3), SOx (80 µg/m3), NOx (80 µg/m3), HF (25 µg/m3), NH3 (400

µg/m3)

(Source: Primary Data Collection and analysis during study period by Laboratory)

1 hr. concentration of CO level was found below 0.1 mg/m3. Overall the ambient air

quality of the study area is meeting the National Ambient Air Quality Standards 2009.

Noise Environment: The day and night time ambient noise level in the study area is

within the prescribed National Ambient Noise Quality Standard for respective residential,

commercial and industrial category at all the monitored locations.

Groundwater: The study area falls in Dakshina Kannada district. Rainfall is the major

source of groundwater recharge apart from influent seepage from rivers, seepage from

canal, irrigated fields and inflow from upland areas. The 10-km study area falls in

Mangalore block of Dakshina Kannada District. Net ground water resources based on

water level fluctuation method is estimated to be 8068.14 hams. Existing gross ground

water draft for all use is 5234.90 hams and over all stage of development is 64.88%.

Overall about 82% area fall in safe category and 18% area falls in critical category.

Ground Water Quality: The pH value of drinking water is an important index of acidity or

alkalinity. pH value of the sample varies from 6.56 to 7.23 in all locations, which is well

within the specified standard of 6.5 to 8.5.Electric Conductivity levels vary from 132 to

302µmho/cm. Total dissolved solids range from 84 to 196 mg/l which is within desirable

limit.The total hardness is an important parameter of water quality. The hardness values

in ground water of the study area ranges between 28 to 84 mg/l which is well within the

desirable limit. The calcium and magnesium values in ground water of the study area are

well within the specified desirable limit of Indian drinking water standard.The chloride

values in ground water of the study area ranges between 17 to 50 mg/l which is well

within the desirable limit.No biological and metallic contamination has been found in any



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of the ground water sample of the study area. Overall the parameters in ground water

sample were well within the desirable limit of Indian Standard IS: 10500-2012.

Surface Water Quality: The sea water quality parameters are compared with water

quality standards for coastal waters marine Outfalls (EPA Rule 1986). The sea water

quality is complying with the Class SW-II of coastal waters marine Outfalls (EPA Rule

1986) which suits for Contact Water Sports and Commercial marine fishing.

Soil Quality: Reddish color soils are observed in the study area. Texturally the soils of

study area are observed as Silty Loam and Sandy Clay Loam Soils.The soil pH ranges

from 6.2 to 7.0, thereby indicating the soils are slightly acidic to neutral. The Organic

Carbon content of soil varied from 0.48 to 0.72 %( 0.83 to 1.24% as Organic Matter)

thereby implying that soils are low to medium in organic content.

Sensitive Ecosystem: No ecologically sensitive area like national park, wildlife

sanctuary, biosphere reserve, forests, wetland are present in the 10-km radius of project

site. No species of plants and animals in the study area were found to be threatened, rare

or endangered.

Land use: The site is located in the Karnataka Industrial Area Development Board

notified Baikampady/ Panambur industrial area, Mangalore, Dakshina Kannada

(Mangalore Industrial Cluster) for industrial land use. Most of the land within the 10-km

area of the project site is Water body and Vegetation/Plantation. As per the land use

based on satellite image, about 30% land in study area is under Vegetation\Plantation,

about 39% of land is under water body, about 21% land is under settlement, only 5% of

the land is under agricultural and rest of the land is under other uses.

Environmental Impact and Mitigation Measures

Air Quality: For the proposed projects, construction of building premises and other

facilities including roads, sewage network, storm water system, and places required are

proposed at the existing site. According to the engineering assessment; most of the

excavated material shall be reused within the proposed project Area. Most of the

construction dust will be generated by the movement of carrying vehicles on unpaved

roads. Unloading and loading of constructional materials shall also act as a potential

source for dust nuisance.

Ammonia Plant:There will not be any significant increase in pollution load due to

increase in production. The plant will operate on Naphtha till arrival of Natural gas at

site. Energy improvement schemes will reduce raw material consumption and emissions

in Naphtha based operation also. Existing plant is already converted to utilize Natural

gas as feed and fuel.

Urea Plant: There will not be any significant increase in pollution load after the

implementation of energy improvement project. Capacity of Urea plant will be increased

from 4,29,000 t/y to 5,69,400 t/y after the availability of NG in Mangalore.



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The emission of Particulate matter from the urea prill tower will be about 110 mg/Nm3

which is well within standard of 150 mg/Nm³.

DAP/NPK Plant: The proposed project will not have any significant adverse impact on

the existing environment as sufficient pollution control measures are incorporated in the

process technology and plant design. The technology also incorporates special

scrubbing equipment like Dual Mole Scrubbing System and also Dedusting system. In

DAP / NPK plant Air pollution control equipment viz. Cyclone, Scrubber, Mist eliminator

etc. shall be installed during the commissioning of the plant itself.

POLY CARBOXYL ETHER (PCE) Plant:

There will not be any gaseous emission from the proposed plant.

Control Measures during commissioning

The control measures proposed to be taken up are given below.

Water sprinkling on main haul roads in the proposed project site will be done, this

activity will be carried out at least twice a day.

The duration of stockpiling will be as short as possible as most of the material will be

used as backfill material for the open cut trenches for road development.

Temporary tin sheets of sufficient height (3 m) will be erected around the proposed

construction site as barrier for dust control.

Tree plantation already present at the site. About 64 acres (33% of total area) is kept

as greenbelt within the project site. Total 63,000 nos. of trees like Teak, Mangium,

Eucalyptus, Subabul, Acacia, etc. are planted at the site. Every year 2,000 saplings

are planted & maintained.

All the vehicles carrying raw materials will be covered with tarpaulin / plastic sheet,

unloading and loading activity will be stopped during windy period.

To reduce the dust movement from civil construction site to the neighborhood the

external part of the building will be covered by plastic sheets.

Given the implementation of proper control measures for dust suppression, no adverse

impacts are expected and compliance with the Ambient Air Quality is achieved at all time.

Noise Quality: Material handling operations and movement of vehicles will be properly

scheduled to minimize construction noise. The machines, mill operations will be the main

sources of noise. All activities will be carried out inside sheds and maintenance program

for equipment will be routinely followed. Workers working in noisy areas will be given ear

plugs. The noise level will be restricted within the plant boundary to meet the standards.

Water Quality: The fertilizer plant requires water for cooling, boilers, etc. No wastewater

will be generated from the proposed projects. Domestic wastewater from plant will be

treated in the existing sewage treatment plant. No wastewater will be discharged outside

the plant premises.



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Wastewater Generation

Ammonia Plant: There is no additional liquid effluent generation from the plant and will

remain zero liquid effluent discharge plant even after the commissioning of proposed

projects. It is proposed to replace the present low pressure stripper with medium pressure

(MP) stripper which will ensure removal of Ammonia from process condensate. The

gases from the MP stripper will go to primary reformer along with steam. The effluent

generated in the plant shall be treated in the existing effluent treatment facility and

recycled back to the system.

Urea Plant There will not be any additional effluent generation after the proposed

energy improvement project. Effluent generation will reduce because of implementation

of various energy improvement schemes. MCF has installed and commissioned urea

hydrolyser stripper and operated for the treatment of effluent streams from ammonia

plant process, urea plant process and condensates from urea plant compressors. The

urea hydrolyser stripper system consists of hydrolyser, which is operated at high

temperature' and high pressure, where urea gets hydrolyzed to ammonia and carbon

dioxide. Ammonia thus produced is separated in the second desorption column. The

liquid outlet of second desorption column contains less than 10 ppm of ammonia and

urea. The ammonia vapours from the second desorption column is fed to the first

desorber. The desorber overhead vapours are condensed in a condenser and reused in

Urea plant.

DAP/NPK Plant There will not be any trade effluent generation from the proposed

DAP/NPK plant. No solid waste will also be generated. Any spillage will be recycled and

reused in the proposed plant. The marginal increase in the water requirement after the

commissioning of DAP/NPK plant will be met by effluent water recovery unit installed.

PCE Plant There will be no liquid effluent generation in the plant. The spillages if any

from the plant floor will be collected and recycled back.

Solid Wastes Disposal: The process of fertilizer production does not generate any solid

waste. All construction waste shall be stored within the proposed site itself. A proper

screen will be provided so that the waste does not get scattered. Attempts will be made to

keep the waste segregated into different heaps as far as possible so that their further

gradation and reuse is facilitated. Materials, which can be reused for purpose of

construction, leveling, making roads/ pavement will also be kept in separate heaps from

those which are to be sold or land filled. The local body or a private company may be

arranged to provide appropriate number of skip containers/ trolleys on hire.

Traffic Impact: The plant is well connected through the National Highway – 66 and

railway wagon facility. The maximum transportation of products are only done through

railway and it reduces the load on road.

Impact on Ecology: Dust emission will be controlled using different air pollution control

devices so that the impact on the surroundings will be minimized. All air emissions from



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the plant will be kept within the prescribed standards. Wastewater and solid waste will be

reused. Greenery is already developed at the site which is about 33% of the total project

site area. Such measures will be adequate to protect the ecology of the area.

Impact on Public Health: The national ambient air quality standards prescribe level of

air pollutants which is safe for public health and vegetation. Air quality dispersion

modeling study proved that the ambient air quality of the area will remain within the

national air quality standards. Hence there will be no risk to public health.

Risk Mitigation Measures

Necessary risk mitigation measures, including firefighting measures will be implemented.

Hazards due to mechanical injury will be reduced by use of standard design and

operating procedures. Disaster Management Plan shall be implemented in consultation

with the District Administration to take care of health and safety during any untoward

incident. Firefighting system with fire extinguishers, hydrant system, sprinkler system,

pumps and pipeline network will be strengthened as per the recommendation.

Project Benefits

The project envisages reuse of wastewater after treatment. By reusing treated

wastewater, MCFL is not only adding value to wastewater but also helping in improving

the overall environment.

At present the total employment is 680 and expansion project will create additional direct

employment for 200 people during the operation.MCFL will employ local people for plant

construction and operation, depending upon the skill and capability. Several other indirect

employment opportunities will be created in the surrounding area. Transport business,

vehicle drivers and attendants, workshops, grocery and retail, medical, school, coaching

centers, technical institutes, restaurants, self-employed persons like tailors, carpenters,

plumbers, electricians, etc. will get indirect job opportunity. MCFL will take up need based

CSR activities to improve the living conditions of underprivileged and make positive

difference in their lives.

Environmental Management Plan (EMP)

EMP for effective management of environmental impacts and ensuring overall protection

of the environment through appropriate management procedures has been

recommended in the EIA report. The capital cost for environmental management of the

proposed project is estimated at Rs 56 Cr and recurring cost aprox Rs. 3 Cr. This amount

shall be used for procurement of pollution control devices, strengthening of environment

Cell, occupation health and safety Cell, greenery development as a part of EMP.

Environment Management Cell (EMC) will ensure that all pollution control devices

function effectively. EMC will supervise disposal of spent oil and waste oil and used

batteries to the authorized vendors. Plantation will be started from day one and continue



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throughout the life of the project. Schemes for resource conservation, rainwater

harvesting and social forestry development will be taken up.

Regular environment, safety and health awareness programs for the workers will be

conducted by the EMC. EMC will also interact with the regulatory authorities, submit the

monitoring reports and consent applications. The implementation of EMP would ensure

that all elements of project comply with relevant environmental legislation throughout its

life cycle.

CSR Activity: Approximate 2.5% of the project cost will be used for Enterprise Social

Commitment (ESC).

Conclusion: The positive side of the project is that no disposal of solid wastes and no

process contaminated wastewater. Besides above, MCF will reuse all the additional

wastewater generated as cooling tower makeup after treating in wastewater recovery

unit. No additional water drawl, no rehabilitation and resettlement is involved. No forest

land is involved and no problems related to sustainable livelihood problems of vulnerable

people are involved.

EMP for effective management of environmental impacts and ensuring overall protection

of the environment through appropriate management procedures has been

recommended in the EIA report. Environment Management Cell will be responsible for

the implementation of the EMP. The impacts are minimized to the barest minimum level

because of proposed mitigation measures and delineation of sound Environmental

Management Plan.

Executive Summary of EIA & EMP Report - KSPCBkspcb.kar.nic.in/PH/EXE-SUM-ENG_MCFL_30112017.pdfPoly Carboxyl Ether project at Mangalore, Karnataka By Panambur ... Ammonium Bi-Carbonate

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